Method for forming building blocks



May 23, 1950 R. G. BELLEZZA METHOD FOR FORMING BUILDINQBLOCKS S@ 2. /3if $5 ,6

a 2 f kx 1 l l l l l l l /w// l Patented May 23, 1950 METHOD FOR FORMINGBUILDING BLOCKS Russell G. Bellezza, Baltimore, Md., assigner to Locke,Incorporated, Baltimore, Md., a corporation of Maryland ApplicationOctober 9, 1944, Serial No. 557,852

4 Claims. 1

The invention relates to a method of forming building blocks, and moreparticularly to a method of forming the same of ceramic material.

Toward the accomplishment of this end, the principal object oi theinvention is to provide a method by which a building block of hollowboxlike formation may be readily, easily and economically manufactured.

Another object of the invention is to provide a method of forming abuilding block having suiiicient structural rigidity, strength orcharacteristics to permit the employment or use thereof in buildingstructures, and possessing at the same time an exceedingly high thermalvalue so that the block serves not only as a construction unit, but asan insulating medium as well.

Other objects of the invention will appear in connection with the moredetailed description of the invention appearing hereinafter whenconsidered together with the accompanying drawings in which:

Figure 1 is a vertical side sectional view of a building block and moldtherefor which embodies the present invention;

Figure 2 is a vertical transverse sectional view taken along the lines 22 of Figure l looking in the direction of the arrows;

Figure 3 is a horizontal sectional view taken along the lines 3-3 ofFigure l looking in the direction of the arrows;

Figure 4 is a side elevational view shown partly in section of acompleted building block removed from the mold;

Figure 5 is an end elevational view having a portion thereof shown insection to illustrate more completely the invention of a completedbuilding block removed from the mold;

Figure 6 is a side elevational view of a modified form of the building.block shown in Figures l through 5 inclusive, and being shown partiallyin section;

Figure 7 is an end elevational view of the modiiied form of a buildingblock shown in Figure 6 and being illustrated partially in section.

Referring now to the drawings in detail, and more particularly toFigures l to 5 thereof, the numeral I indicates a portion of a mold incross section, comprising transversely spaced side plates 2 and 2aextending preferably for the full area or height oi the mold, and havinginterposed therebetween angularly disposed intermediate sections orplates 3 and ta which have their contiguous extremities mitered as at 4to present a completely enclosed box-like structure dening amaterial-receiving area or cavity 5 therebetween. Positioned at thecentral portion of each intermediate section 3 and 3a and desrablyoutstanding therefrom at the corners thereof is a lug 6 which extendsintoV a correspondinglyv a proper assembly thereof as well as retainthem in a predetermined relation or assembly. Any' clamping means (notshown) may be employed to act transversely or horizontally of the mold,

urging the side plates toward one another.

The mold I is formed of plaster of Paris which has an interiorconguration to agree with or conform to the desired conformation of theeX- terior of the object to be formed or, as in the instant case, abuilding block generally indicated by the reference character 8. Anaperture or access opening 9 is provided in one of the intermediate moldsections in desirably the upper- 'most portion thereof through whichfluid ceramic material may be introduced. The fluid ceramic material ispoured into the mold until it completely fills the same and, by reasonof the abvsorbent characteristics of the plaster of Paris,

the iluid, carrier or water mixed into or forming a part ofthe fluidceramic material Ais absorbed by the mold structure. This absorption bythe mold structure. therefore, causesthe ceramic material adjacent theinner dening walls of the -mold structure to become hardened 'orsolidified.

It will be noted that the opening 9 is of considerable dimension so thatit may form a reservoir or well to hold suicient iluid ceramic materialto be drawn from during the absorption period and thereby insure acomplete filling of the interior of the mold structure.

After a predetermined period, hardening of the ceramic material willcontinue and progress inl wardly of the mold structure so as to form ablock structure such as illustrated at 8. When the walls of the buildingblock have reached a thickness such as that illustrated in the drawings,the mold is inverted from the position shown in Figures l and 2 so as topermit the fluid ceramic material to be discharged or escape from theinterior of the thus formed block and mold through the opening 9. Thisprocedure, therefore, leaves the ceramic building block with side andintermediate or connecting walls Il) and Il respectively, with acontinuation of the opening The lugs and dowels form an in-' terlockbetween the respective plates for insuring 9 extending through one ofthe connecting walls, as indicated by the diagrammatic lines l2 inFigures 1 and 2. While the mold is in this inserted draining position, aplug i3, which may also be of plaster of Paris, is inserted into theopening 9 after the major portion or substantially all of the fluidceramic material has been discharged irom, the: mold.'l Aften the;insertion ofi the plug I3; acontinuedfdraining-of the interiorof themold will result in the aperture l2 being lled with fluid ceramicmaterial to also becomebeing lifted; oi of; the:v remaining intermediatesection*- or ip latei` Atrthis; stage ofthe procedure;A the hardened-'ceramici materia-l formedv by, the aperture I 2 which extends:v abovethe, plane of the associated connecting` wall, may -be Asevered-by`meansgoia wireorfanyfotherfcutting means. The.; buildingblock is; then:allowedto` dry.` to what is commonly known or-termed; as a bonedrystate, atzwhich'time an orifice; Meis formed inv theblock and-1comprises an, outer. portion thereof conically shaped; andaninnenportion thereofcylindrically. formed; of; a veryfminute` or smalldiam,- eteror.; bore; Glazing: material is thenapplied; to,V outer or-frontandrear surfaces or; facesl5; of theblocleaswell asV to thedefining surface ofitl'lej-conicallS/` shapedrpprtion of' the oriiiceThe block is'then in` condition forv itsfinal,L step ofY formationwhichfis thearingoperation. Itwill; beV noted that the side' walls. l0areYV of slightly greater4 extent than: the parallelogram as s definedby thev intermediate orV connectingy walls ll` so thatithere isformed oneach side oi-the blocka. continuous or uninterruptedvilange l5: whichextends beyond? the planer of the .intermediate wall andthereby.- formsacavity |11 for theireception of any typeof bonding or: binding.material employed during theA assemblage of a plurality offv blockslin awall'structure.k

Extending in opposite directions: from. transverselyspaced'intermediatefor connecting walls@ are staggered'studs or.I spuds I3formedl integralA with the block; These spuds form ring feetV` uponwhich, during they ringoperation ol"4 the ceramicV block, the latterlvis adapted"v to. rest. Whenglazel materialis: applied to thefaces |51itfwill'be noted that'ifY the glazing materialV should.. come int'oContact with a support orsagger: (not. shown) during the ringfoperation, the` glaze would form a bond between the blockV and thesagger resulting in the completed glazed block beingbroken ordamaged Yin removing the block fromY the sagger. Byproviding;y the iiring` feetfere with one another during an assemblage of blocks in the formation ofa wall structure.

Prior to the ring operation of the block, there is, as previouslyrelated, a particularly shaped oriiice I4 formed in one of theconnecting walls and having the defining surface of the conically shapedportion thereof covered with a glazing material1 sothatduring theringoperation of theblock, the air entrapped within the block will befree to escape through the orifice and, as the iiring operationcontinues or progresses, more and moreair will be driven or forced outof the hollow interior cf'the block until nally, at approximately theVtemperature of vitrification of .the glazing.; material, a very small orminute amountofair willYT be present in the block. At this stage of thefiring operation, the glazing material'willcreepor progress toward thecylindricaLpoition of the orifice Il! and, since this portion has beenmadefso small as to prevent the glazingmaterial from flowingvtherethrough, the :latter will become solidied in approximately theposition as illustrated in Figures 4 andl 5,l

to form a seal closing the oriiceinto the blocka-nd causingasubatmcspheric conditioner high vacuum. to.be; created within theblock. This subat mospheric condition within the block or;- the dead airspace within each block serves as; an insulatingV medium against thetransfer of either heat `or cold from one sidewall to the other.

When theblock is formed of porcelainclayn4 the high density of.y theblock forming material. will preserve thevacuum within the-block ferait.

indelinite period. If, however, the block. is,- formed. of; a moreporousl ceramic material, air; may enter through the pores thereof tothe inf. terior of the block, but even in thislatter event, there isformed within-theinterior of the block a.

deadvair, space which functions as an insulating,

medium andwhile not as effective as a vacuum; still possesses very highinsulating qualities. or thermal values.

If itis desired touse the blocks or portions thereof as a facing for awall, the block, after',- being formed,A may besevered on thediagrammatic line'A-A of'Figure 5, and the projecting'A portions of theconnecting walls, after the-block: hasbeen red, `form means for bondingAthefacingy with a plaster or cement coating as is- Com-- mon inconnection with the layingl of,` tile; and need ynot be furtherdescribed.

Referringv now toliigures and 7 of thedraw-4 ings, wherein a modifiedform of the invention is illustrated, a building block 2liv is shownpar- 55 tiallyfin section and removed fromga, mold. They building blockis somewhat similar to theymold... described in connection with thefirst species. of` the invention and which is, except forthe slightmodifications: hereinafter noted, employed to'v .a formv the modifiedblock. In the modified formv of the invention, it will be noted that inVplaces of thestuds I8, there has been provided inclines or tapers 2l. onallor at least the lowermost exeY tremities offthe flanges 2,2. Theseinclines inthe.,-

01 'Spudsf the glaze maybe extnded to the Very 65, presentnstancepresent firing feet 23 upon which limits of the faces I5; and'since the spuds are of a height desirably o r approximately one and'Aone-half; times the depth ofthe adjacent flange, the lowermost portionof thefl'ange.. Will be. re.

the blockresteduring theliring operationV of the block. When applyingthe glazing material to.Y theouter. surfaces. 240i the block,thermaterial isv not applied beyond or lower than approxiY tained in.anY elevated. position. relative to. the ml matelytheposition orlocation indicated at.25..in

sagger and thereby avoid any adherence be tween, the flanges or bloclrandthe saggel? dur.-` ingfthe ,-iiringA yoperation.l llhe ,Spuda as,Vindicated, l'rereinabove,I are staggered, as most, clearly il,-v

Figures. 6. and 'LwhichVA will leave the balance-'cfrv the taperV or`incline unglaaed to thereby avoid.

adherence between the yblock and` sagger.

Inthe presentform. also the4 outer, surfaces;v

lustrated inliigure sothat they may not inter- 'U5 il!!A areoflpyramidal form, as clearly indicatedjn;

the drawings, which enhances the ornamental appearance of the block and,more specifically, materially increases the strength of or rigidiiiesthe block against not only service stresses, but also the atmosphericcondition existing within the block.

If desired, outer surfaces of the connecting walls of both blocks may beprovided with a sanded surface, as shown at 2'6 in Figure 7, which iscommon in connection with insulators. This surface `is formed by glazingthe surface and, while the glazing material is in the moistened state,causing sand to engage with the surfaces to which it will adhere byreason of the adhesive qualities of the glazing material. When the blockis red, owing to the fusion to the glaze, the sand is rmly connected tothe walls and forms a bond for mortar or cement by which the blocks maybe connected to form a wall or ceiling structure.

It will, of course, be noted that since the block is a product ofcasting, any configuration may be formed on the faces I5 of the firstspecies of the invention, and 24 of the second species, and further,that various changes and alterations may be made to the illustrated anddescribed construction without departing from within the spirit of thepresent invention and the scope of the appended claims.

I claim:

1. A method of forming a hollow building block of ceramic materialemploying a mold cf plaster of Paris or the like, having the wallsconforming to the shape of the finished block and a filiing openingtherein, comprising filling the mold cavity with iiuid ceramic materialthrough said opening, allowing the material in contact with the walls ofthe mold to harden for a limited time, removing from the interior of theblock the greater portion of unhardened fluid ceramic material throughsaid opening, placing a plaster of Paris plug in said opening andcausing the remaining fluid ceramic material to completely iill andharden in the opening in said block forming a, continuation of saidlling opening, removing the block from the mold, permitting the block soformed to dry, and finally firing said block to vitrify the same.

2. The method of forming a hollow building block of ceramic material,employing a multipart closed mold of moisture-absorbent material havinga filling opening therein, comprising lilling said mold with ceramicmaterial in fluid form, allowing the ceramic material in proximity tothe walls of the mold to harden, pouring out of said opening the greaterportion of the remaining uid ceramic material, inserting in said openinga, plug of moisture-absorbent material, causing the remaining fluidceramic material to completely fill and harden in the opening in saidceramic material forming a continuation of said opening in said mold,opening the mold, removing the block from the mold, permitting the blockso formed to dry, adding a glazing material to opposite side facesthereof, and finally ring the block so formed to vitrify the same.

3. The method of forming a hollow building block of ceramic materialwith a dead air space lwithin the same, employing a multi-part closedmold of plaster of Paris or the like having a iilling opening,comprising filling the interior of the closed mold through said openingwith fluid ceramic material, permitting the material adjacent the wallsof said mold to harden to form a block having walls of substantiallyuniform thicknessV'removing through said opening the greater portion ofthe bulk of the unhardened ceramic material, plugging said opening andallowing the remaining unhardened ceramic material to completely closethe opening in said block inserting a plaster of Paris plug in saidopening, causing the remaining fluid ceramic material to completely filland harden in the opening in said ceramic material forming acontinuation of said opening in said mold removing the mold, forming anorifice in said block, permitting the block so formed to dry, applyingglazing material to the opposite side walls and to the periphery of saidoriice, and firing said block to vitrication whereby the glazingmaterial lls and seals said orifice.

4. The method of forming a, hollow building block of ceramic materialhaving a vacuum created in the interior thereof, employing a multipartclosed mold of plaster of Paris or the like having a filling opening,comprising lling the closed mold through a suitable opening with uidceramic material, permitting the material adjacent the walls of saidmold to harden to form a block having walls of substantially uniformthickness, removing through said opening the greater portion of the bulkof the unhardened ceramic material, plugging said opening and allowingthe remaining unhardened ceramic material to completely close theopening in said block inserting a plaster of Paris plug in said opening,causing the remaining uid ceramic material to completely fill and hardenin the opening in said ceramic material forming a continuation of saidopening in said mold removing the mold, forming an orice in said block,permitting the block so formed to dry, applying glazed material to theopposite side walls of the block and to the defining surface of saidopening, and iiring said block to vitrification whereby the glazingmaterial in said orifice fills and seals said orifice.

RUSSELL G. BELLEZZA.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 2,015,681 Kesty Oct. 1, 19352,070,672 Moczala Feb. 16, 1937 2,106,415 Purinton Jan. 25, 19382,224,488 Rendall Dec. 10, 1940 2,226,220 Cox Dec. 24, 1940 2,277,507Benner et al Mar. 24, 1942 2,277,543 Downs Mar. 24, 1942 FOREIGN PATENTSNumber Country Date 6,699 Great Britain A. D. 1914 479,157 Great BritainFeb. 1, 1938

